Thermostatically controlled electrically heated iron



Feb- 14, 1939- N. F. T. SAUNDERS ET AL 2,146,992

THERMOSTATICALLY CONTROLLED ELECTRICALLY HEATED IRON Filed larch 14, 1936- 2 Sheets-Sheet l 7; ven fors; M1? 7:15 /9UM/9BQ Feb. 14, 1939- N. F. T. SAUNDERS ET AL 2,146,992

THERMOSTATICALLY CONTROLLED EIJECTR-ICALLY HEATED IRON Filed March 14, 1936 2 Sheets-Sheet 2 Patented Feb. 14,1939

UNITED STATES PATENT OFFICE mauosrsrrcmr oomousn mormoswr HEATED mos Application March 14, 1938, Serial No. 88.886 In Great Britain March 19, 1935 1a cam (Cl. 219-25) This invention relatesto thermostatically controlled electrically heated irons and in particular irons of that kind in which a switch in the electrical heating circuit is opened and closed, as

the temperature of the iron rises and falls, by a heat sensitive device such as a bi-metallic strip arranged within the iron.-

' In some irons of this kind already known, the

arrangement of the heating elements and the thermostat is such that the latter is influenced not only by the temperature of the heated sole plate but also to a very considerable extent by heat radiated directly by the heating elements and by the general temperature conditions within the body of the iron'and while these arrangements maintain the temperature of the body of the iron as a whole more or less constant, it is found that under load the temperature of the working surface of the sole plate tends to fall as the load is increased.

It will be readily understood that when an iron is under heavy load the heating current circuit should be closed for longer periods. With some known irons the thermostat control issuch that the periods during which the heating circuit remains closed are, under such circumstances, somewhat lengthened, but under the direct influence of the heating elements and the body of the iron, which also under such circumstances of necessity becomes hotter, the heat sensitive device is nevertheless caused to open the switch before suillcient heat has been generated to wholly replace that extracted from the sole plate by the work. In some irons this resultant "working drop in temperature of the sole plate is very considerable when the load is heavy and the temperature addustments, which are usually effected when the iron is not under load, are rendered unreliable.

If the temperature setting is made by the operator so that ,the sole, plate is at the desired working temperature when the iron is at rest, the temperature of the sole plate will fall below the desired working temperature when the iron is applied to the work, whilst, if the setting is such as to raise the temperature in the rest position higher, with a view to allowing for the working drop, the temperature of the iron when off the work may become excessive and dangerous.

Various attempts have been made to construct irons so that the direct effect ofthe heating element and of the body of the iron upon the heat sensitive control device is reduced, in order to reducethe "working temperature drop, but it is found that arrangements directed to this end prevented.

have hitherto given rise to a further difiiculty'in that the working surface tends to become excessively hot during the period when the iron is heating up from cold, with the resultant risk of damage to the work if the iron is applied during 5 this initial heating up period.

This trouble arises in these known irons from the fact that the transfer of heat to the heat sensitive device takes place mainly by conduction through the sole plate and over a long heat path, so that the heat sensitive device is caused to heat up more slowly than'the working surface and the latter therefore reachesan excessive temperature before the heat sensitive device is hot enough to open the switch in the heating cir- 1 cuit. This eflect is. also noticeable when the temperature setting of the iron is altered to raise the working temperature to a higher value.

The primary object of the present invention therefore, is to provide an iron in which the "working temperature drop. even under heavy load, is kept within limits, the difference betweenwhich cannot be detected by the usual methods employed by an operator and in which the attainment of an excessive temperature by the sole plate when the iron is oil the work is A further object of the present invention is to provide an improved iron of the kind embodying heat sensitive means for opening and closing the electric heating circuit as the temperature of the iron varies and a manual control device whereby the temperature at which the switch is opened and closed my be varied to control the average temperature of the iron according to the nature of the work to bedone, with a manual control which does not become excessively hot and which is located in a position where it does not interfere with the hand of the user.

In accordance with one feature ofrthe inven- I perature chanses are determined mainly by va i tions in temperature ofthe sole plate and the other of which is mounted and arranged so as to be effected by the general temperature of the space within the iron. The two elements are arranged to operate in opposite senses, that is say, while a rise in temperature of the first. element tends to open the switch in the heatins eiras cuit, a rise in temperature in the second element tends to maintain the switch closed.

Thus when the temperature within the body of the iron rises, as when the iron is under heavy load, the second element becomes correspondingly heated and functions to delay the opening of the switch by the first element until the heat taken from the working surface has been wholly replaced. On the other hand, during the preliminary heating up of the iron from cold, the second element heats up less rapidly than the first element and causes the switch to be opened earlier and before the sole plate has become excessively heated.

In accordance with another feature of the invention an electrically-heated flat iron of the kind indicated above'is provided comprising a sole plate, a. temperature control means, a movable element forming part of'said control means within said iron, an elongated, manual control device cooperating at one end with the said element, means for mounting said manual control device in substantially parallel relationship with the said sole, a body including a handle and formed to enable the other end of said elongated manual control device to extend therethrough; and to be disposed at a point to the rear of said handle for engagement by the operator.

The manual control member is formed wholly or partly of heat insulating material and a long and low heating conducting path is thus provided between the electric circuit controlling mechanism and the control knob or handle provided outside the body of the iron. The knob or handle of the control device being located to the rear of thehandle of the iron, the hand of the user of the iron is not obstructed or interfered with.

, Two embodimentsof the invention are illustrated by way of example in the accompanying drawings, in which Fig. 1 is a plan view of the improved iron with I the top or body portion removed.

Fig. 2 is a sectional side elevation on the centre line of Fig. 1 the outline of the top orbody of the iron beingshown in dotted lines and Fig. 3 is a side view on a larger scale showing the arrangement of the temperature controlling parts.

Fig. 4 is a sectional elevation on the line 3-4 p of Fig. 3.

Fig. 5 is a plan view ofa modified iron with the body removed.

Fig. 6 is a sectional side elevation of a complete iron shown in Fig. 5.

Fig. '7 is a rear end elevation with the bodyremoved and Figs. 8, 9, 10, 11, 12, 13 show constructional details of the iron shown in Figs. 5

rounding strengthening flange 2.

The inner surface of the sole plate i is recessed longitudinally in the region of its centre as shown at 3, and in this recess is located a bi-metallic strip 4, one end of said strip being anchored in intimate thermal contact with the sole plate, being held in position by a block 5 of insulating material,- while the other end of said strip i is bent so as normally to be slightly spaced from the sole plate I. The free end of strip 4 carries a U-shaped member 6 of metal so mounted that the limbs of the U extend across and are parallel to the strip 4. The member 6 is insulated from strip 4, mounting being effected by clamping one limb of member 5 between a lower strip of mica or the like I and an upper'insulating block 8 and riveting the mica I and block 8 to the bi-metallic strip 4. The strip 4 is arranged so that its free end bends upwards and raises U-shaped member 6 when the temperature of the strip 4 rises. On the underside of the upper limb of member 6 is provided a contact stud 9 and the member 6 is itself connected through thin corrugated metal conductors Ill, such as will offer a minimum of resistance to movement of the end of strip 4,

to one of the current supply terminals l l.

The heating element l2 may be of usual form comprising a coil of resistance wire enclosed between two sheets of mica centrally apertu'red so that the element may lie close to the inner surface of the sole plate I within flange 2 and around the central recess 3 in said sole plate. The heating element I2 is clamped to the sole plate 5 by means of a flat metal weight i3 pref- 4!, is mounted one end of a flexible metal strip H, anchorage being effected by means of a further insulating block it and the anchored end of this strip H is electrically connected with one terminal E9 of the heating element l2. Beneath the free end of'flexible strip I7 .is fixed a bi-metallic extension strip 20, said e'xtension strip being'arranged between two strips 2| and 22 of mica and the whole riveted to the end of strip ll.

The bi-metallic extension strip Zil is further from the sole plate land the heating element l2 than the first mentioned bi-metallic strip 6, so that it is less directly influenced by changes of temperature in the sole plate. The mica strip 2! serves to prevent or reduce heat transfer by conduction from strip IT to strip 20 and the mica strip 22 serves to shield strip 20 from heat radiated from heating element H2. The bi-metallic strip 26 is arranged so that its free end tends to bend downwards as it becomes hotter.

- On the upper side of the end of strip H is mounted a metal plate 23 hearing a contact stud 2 1 for engagement with stud 9 on mil-shaped member t. V

The electrical circuit is completed by connecting the other terminal 25' of heating element l2 with the other heating supply lead 2t.

The flexible metal strip I l is given an upward set so that contacts 9 and 26 may be kept together over a given range of movement of the bi-metallic strips 6 and 2B and until temperature conditions become such as to. require the heating circuit to be broken.

Over the parts so 'far described is mounted a metal yoke 25 disposed longitudinally of the iron the front end being slotted for the passage of the bi-metallic extension strip 20 and the parts of the yoke at each side of the slot beingscrewed to bosses 26 provided on the sole plate i. The rear .end of the yoke 25 seats upon a strip of insulating material 2'I placed above theends ofconductors It on insulating block I3. The yoke 23, is somewhat wider than the blocks I3 and 3, and bolts 23 passed through the rear end oi said yoke 25 and into bosses 23 on the sole plate I serve to. maintain the yoke 25, insulating strip 21, conductors I3, block I3, \ilexible metal strip I1, block 3 and bimetallic strip 4 in position.

The front and rear ends of the yoke 25 are apertured to form bearings for a horizontal or slightly inclined spindle 33 the-forward end of which bears a snail cam 3| formed of insulating material and adapted to engage the free end of bi-metallic extension strip 23.

The rear end of spindle 33 extends towards the rear of the iron and is formed to receive the shank 33 of a control knob 33 formed of heat insulating material, and arranged close to the rear wall of the body 34 oi the iron with the shank 32 extending through a hole in said body into the interior of the iron.

A spring 38 carried by a collar 33fast on spindle 30 may be arranged to engage in a groove 43 in shank 32 to eifect driving engagement between spindle 30 and control knob 33.

Any convenient form of iron body 34 may be used, but in the embodiment shown a body and handle is formed of a one piece moulding of glass, porcelain or other low heat conducting mouldable material. A glass or porcelain body, for example, possesses the advantage that its own weight renders unnecessary the use within the iron oi large metal weights which might adversely aifect the temperatures of the bi-metallic controlling members.

The. body may be secured to the sole plate in any convenient manner as for example by means of bolts 35 engaged in recesses in the iron body and screwed into bosses 33 extending upwards from the sole plate I. The recesses in the iron body may be filled by thumb pieces 31 of suitable material which while concealing the endspi the bolts 35, afford ready access thereto in case of necessity.

In use the control knob 33, which may bear indications such as High", "Medium and "Low,

according to the temperature to which the iron is to be heated for the work in hand, is rotated and the snail cam 3| on the spindle 33 thereby set to form a stop to limit the upper position of the bi-metallic extension 23 on the flexible metal strip I'I as required.

While the ironis cold the cam does not contact with the bi-metallic extension strip 23 so that the contact studs 3 and 24 remain together as shown in Fig. 2.

If now the current is switched on the heating element 2 becomes hot and transmits heat to the sole plate I. The first mentioned bi-metallic strip. 4 being anchored with one end in contact with the sole plate I commences to heat up also by conduction.

In an ideal thermostatically controlled iron the heat sensitive device would at all times be at the same temperature as the working surface of the sole plate, but in existing irons. the thermostat control, which is of necessity contained within the body, is considerably affected by temperatures obtaining therein and in such a manner as to give rise to difliculties indicated above.

With the improved iron according the pres-,

ent invention during the preliminary heating up period the temperature risein bi-metallic strip 4 ,lags with regard to the temperature rise of the working surface of sole plate I. As the. end of strip 4 with U shaped member 3 rises, however,

.the second bi-metallic strip 23 on the end of flexible metal strip rises also under the lift imparted by the latter and so contacts 3 and 24 remain together and the heating circuit remains closed luntil the end of bi-metallic strip 23 engages cam 3 During this preliminary heating period however, the bi-metallic extension strip 33 which is insulated from the sole plate I and shielded from direct radiation by heating element I2 heats up more slowly than the main by-metallic element'4. The arrangement is such that during this period the extremity ofstrip 20 is bent upwards relatively to its position when hot as under the latter working conditions, and it therefore contacts sooner with the cam 3| and the contacts 3 and 24 are parted earlier and before the working surface of the sole plate I has reached an excessive temperature.

As the whole iron warms up, the bi-metallic extension 20 bends downwards to gradually vary or delay the point at which contacts 3 and 24 open so that after two or three cycles the normal conditions appropriate to the setting ior'the working conditions is reached. During these cycles, the sole plate temperature is kept within limits, the difierence between which cannot be detected by the methods usually employed by an operator.

In use under heavy load when the switch contacts 3 and 24 remain closed for long periods due to rapid extraction of heat from the sole plate I, the temperature in the interior oi. the body of the iron' and therefore that of bi-metallic extension strip 20 becomes higher, and under these conditions the end of bi-metallic exten-.

, of the iron which must necessarily exist during the rapid transfer of heat to the working surface, to be maintained.

It is found that byfusing a heat sensitive control means such as that described above and a thinner sole plate than has hitherto been used, the fluctuations in temperature of the working surface when the iron is in use and the control appropriately set are kept within such close limits as to be incapable of detection by the methods employed by theordlnary user.

The arrangement of the control knob 33 at the rear of the iron body 34 as described, possesses, the advantage that it cannot contact stituted by one or more flexible capsules in the form of sealed corrugated gas containing bellows which expand 'or contract as the temperatures vary, to operate the switch. contacts.

In the form of iron shown in Figs. 5-13, a sol plate I is provided with a central longitudinal recess 2 in which is mounted a bi-metallic strip 3 anchored at' the end towards. the rear end-of the iron asfor example by spot welding.

A heating element which may comprise a winding on a mica or like former and sandwiched between insulating strips, the whole being enclosed in a fiat envelope 4 of metal such as steel, is mounted in contact with the upper surface of the sole plate I, being clamped in position through a metal clamping plate 5 preferably with the interposition of a sheet 6 of asbestos. The clamping plate 5 is held down by means of bolts or screws I I taking into the sole plate I.

end of bi-metallic strip 3and its rearwardly The heating element 4, asbestos sheet 6 and clamping plate 5 are also longitudinally slotted at the centre and in the space formed by these slots is housed the automatic switch in the electrical heating circuit of the iron.

This switch and its mounting are constructed as iollowsz- Across the rear end of the slot in clamping plate 5 is mounted a bridging plate 8, said plate being held in position by the rear screws 1' and further screws 9 taking into the clamping plate.-

bent upwards and rearwards as shown at III'.'

to embrace the free end of the upper strip "I I. Strip III is provided on its underside with an insulating stud I4 for engagement with the free turned extremity bears a contact stud I5 for engagement with the free end of strip II.

The free end of lower strip I is biased downwards and the free end of upper II upwards, so

- that the switch contacts tend to remain closed.

V as

extension 22 and a coiled spring 28 is provided 'The rear end of lower strip I0 is clamped in contact with a metal connecting piece I which in turn is connected through a strip I8 with one end oi the winding of the heating element 4.

The-rear end of the upper strip II is clamped in contact with a metal connecting piece 16' which'extends upwardly to a point convenient for the connection of one of the supply leads thereto by means of screw I I. A further upstanding strip I8 is connected with strip I8 with the interposition of insulating material I9, this strip I8 at its lower end being connected through a further metal strip 20 with the other end of the winding of the heating element 4,

whilst its upper end'is adapted for the connec- 4 tion of the other supply lead through screw 2 I.

The means whereby the mean temperature of the iron may be controlled at the will oi. the operator will now be described.

The forward end of bridging plate 8 is provided with an extension 22 which is of thform in section, and the limbs 23,- 24 of the U are apertured to iormbearings for a'metal spindle 25 arrangedto extend longitudinally of the iron and on the forward end of which is fixedly-mounted a snail cam 26 oi. a-shape such as is shown in fig. 4 and formed oi. insulating material. This cam 28 occupiesa position where its periphery is adapted to be engaged by the upper switch strip II. A collar 21 with a set screw is provided on the spindle 26 totherear of limb 24 of between the collar 21 and limb 24 to-maintain spindle to rotate it. Driving engagement is provided by a spring 32 (Fig. 11) extending from the collar 2'! fast on spindle 25 and engaging in a longitudinal groove 33 formed in the surface of shank 3|.

The body 34 of the iron, together with the handle 35 is formed in the case illustrated of a one piece moulding of ceramic materiaLsuch as glass, porcelain, china or the like, the interior being shaped to provide space for the above described parts and including a housing at the rear end for the upstanding strips I6 and I8 for connection with the current supply leads. This housing may be closed by a cover 36 of any convenient form and fixed in position in any convenient manner. The rear wall 31 of the body is apertured as shown at 38 for the passage of the shank 3| of control knob or handle 30, said shank being inserted in the aperture 38 and ap; plied over spindle 25 after the body of the iron has been secured to the sole plate.

Connection of the body 34 of the iron to the sole plate I may be efiected by means of a bar 39 the ends of which engage between lugs 40 (Fig. 12) formed at the rear end of clamping plate 5, said bar bearing a pair of fixed bolts 4| which extend upwards and through apertures in a lug 42 provided on the inside of the rear wall of the body 34, nuts 43 with the interposition of springs 44 being applied to their upper ends.

At the front bolts 45 are passed down through the bottom of recesses formed in the body of the iron at each side or the handle into-internally screw. threaded bosses 48 on clamping'plates 5. The recesses may be closed by/means of stud 41 of heat insulating material preferably held in positionby spring clips 48, so that they may be readily removed to give access to the bolts 45. These studs are shaped as shown in Fig. 13 to form thumb rests. Y

'A strip 48 of resilient material such as asbestos string may be inserted between the sole plate I and iron body 34. In operation the heat of the sole plate I is transmitted by conduction to the bi-metallic strip 3 and the free end of the latter is caused to rise as the temperature of the sole plate increases. a

The bi-metallie strip being in 'contact with stud I4, the free end of lower-strip I 0 is raised and owing to'the upward set ofstrip II the latter remains in contact with stud I5 to maintain the heating circuit closed until strip II engages cam 26; whereupon further upward movement of strip II is prevented and the switch is opened.

As the sole plate cools the bi-metallic element 3 bends downwards and contact between stud I5 and strip III is re=established.

It will readily be seen that by rotation of the cam 28 through the control knob 30, the point in the upwardmovement oi' the end of bl-metallic strip 3 and thereiore'the temperature of the sole plate I at which the switch will open, can-be varied at the will of the operator, and according to the nature of the work to be done.

The arrangement of the control knob 30 outside the body or the iron and behind the rear tion corresponding to the indicated wall thereof permits a long heat conducting path between said knob 30 and thecontrol cam 23 and the'related parts situated near the centre of the iron so'that the knob ll does'not become excessively hot. Furthermore, the locating oi the knob is such that it does not get in the way of the fingers of the user as would be the case it it were mounted for example above the body 01 the iron and beneath the handle.

It will be understood that instead or a metal spindle 25 between camfii and the knob 30 and shank ll of insulating material, a spindle 25 also of insulating material may be used.

The means employed for efiecting driving engagement between knob 30 and spindle 25, comprising the adjustable collar 21 and springs 32 last with said collar and engaging in the groove 33 in shank 3|, ofiers the advantage that the setting of the cam 28 with regard to switch member II can be readily effected at the works and the knob 30 then arranged in appropriate posiheat conditions. I

For this purpose the set screw in collar 21 is loosened and the spindle 25 rotated to bring the cam into the desired position. Thereafter the collar 11 is rotated on the spindle to locate the spring .lland the knobv 10 so that markings on the latter are in proper relationship to a setting mark provided on the back wall oi the iron body.

We claim:

1. A thermostatically controlled electrically heated iron, including a body having a sole plate, a switch for its heating circuit and control means for said switch, said control ,means comprising two cooperating heat sensitive elements, one of said elements disposed remote from said sole plate so as to be affected by the temperature conditionswithin said body but being substantially independent from electrical heating current if trav-f ersed thereby, the other one of said elements disposed adjacent to said sole plate in direct heat conducting relationship therewith.

2. A thermostatically controlled electrically heated iron including a body having a sole plate, a switch for its heating circuit comprising two contacts and a control means for said switch, said control means comprising two cooperating heat sensitive elements capable of changing their shape depending upon temperature changes, and mounted substantially parallel to each other and to said sole plate, one of said elements in direct heat conducting relationship with the latter and the other spaced therefrom and being substantially independent from electrical heating current if traversed thereby, said switch contacts carried by said elements, said elements arranged to move said contacts in opposite directions if the shape of said elements is changed under the influence of increasing or decreasing temperatures.

3. A thermostatically controlled electrically heated iron as in claim 2, including an adjustable stop disposed in the path of said second-mentioned elementior varying the temperature setting oi the iron.

4, A thermostatically controlled: electrically heated i'ron, including a body, having a sole plate,

a switch for its heating circuit and control means therewith, asupport on said element, a switch' contact on said support, .a second heat'responsive element arranged above said first mentioned element so as to be aiiected by .the temperature coilditions within said body, but being substantially independent from electrical heating current ii traversed thereby, a switch contact carried by said second element adaptedto engage the contact carried by said first mentioned element, an adjustable stop disposed in the path of said second mentioned element iorlimiting its upward movement in any one of a plurality of positions desired, and means within the reach of the operator for adjusting said stop.

5. In a thermostatically controlled electrically heated iron as described in claim 4, said adjustable stop comprising a cam arranged with its periphery in the path oi said second mentioned ele-' ment, a rotatable rod secured to and supporting said cam, a rotatable handle projecting irom an end of said body and operatively connected with said rod.

6. In a thermostatically controlled electrically heated iron as described in claim 2, said heat sensitive elements each comprising a bi-metallic strip and aresilient member supporting the upper one of said strips, said resilient member having an upward bias whereby for a predetermined period said elements ,move in unison with one another.

'1. A thermostatically controlled electrically heated iron including a body, having a sole plate,

a switch ior its heating circuit comprising two contacts and control means for said contacts, said control means comprising a i i-metallic strip mounted adjacent to said sole plate, said strip on one end in direct heat conducting relationship with said sole plate and carrying one 01 said contacts on its iree end, said contact to be raised as the temperature of the strip increases, a fiexible metal strip, one end of said metal strip anchored spaced from said sole plate and said body, and having an upward bias imparted thereto, the other one of said contac carried by said metal strip and disposed in 9. tion to be engaged by said first mentioned contatt, a bi-metallic extension strip carried by said flexible metal strip, and an adjustable stop disposed in a position to be engaged by said last mentioned bi-metallic strip.

8. An electrically heated iron oi the kind indicated comprising a sole plate and its temperature controlling means, a movable element forming part or said control means within said iron. an elongated manual control device, one end oi which is adapted to co-operate with said element, said manual control device arranged substantially parallel to said sole plate said controlling means and manual device mounted on said sole plate, a body including a handle, the other end of said elongated manual control device extending through and beyond said body through an end thereof within reach 01 the operator.

9. An electrically heated 't iron according to claim 8, whereinthe man 'control device comprises a rotatable spindle arranged longitudinally within said iron, a cam fastened to the inner end of said spindle, said cam iorrning a stop for limitfree end of said bi-metallic strip, said switch eleing the heating element in position, means provided on said clamping plate to support switch bearing members for said control device and 'con-= necting strips for connection with the current supply leads.

12. An electrically heated flat iron according to claim 8, wherein the manual control device comprises a rotatable spindle, a cam flxed at one end thereof, a control knob carried by said spindle, a collar adjustably mounted on said spindle, a member fast on said collar and engaging a recess, 01'

groove, in said knob, thereby coupling said knob and said spindle.

NORMAN FRANK 'I'ILBURY SAUNDERS, NORMAN BARNES. FREERICK JOSEPH MUDGE. 

